JPWO2012131934A1 - Insulated wires and coils - Google Patents

Abstract

An assembly line (11) in which nine metal-coated copper wires (4) having a non-circular cross-sectional outline are gathered to form a square cross-sectional outline, a first insulating coating (1), and a second insulating coating ( 2) and a third insulating coating (3), and the metal-coated copper wire (4) forms a metal coating (4b) of tin or tin alloy or zinc or zinc alloy on the outer periphery of the copper wire (4a). It is a thing. A copper alloy wire, an aluminum wire, or an aluminum alloy wire may be used instead of the copper wire (4a). Loss can be reduced on average in a wide band from direct current to high frequency.

Description

  The present invention relates to an insulated wire and a coil, and more particularly to an insulated wire and a coil having a small average loss over a wide band from direct current to high frequency.

  Conventionally, multiple conductors with non-circular cross-sectional contours are gathered together in an arrangement in which adjacent conductors are insulated by an enamel layer, and the entire contour is circular, and the outer periphery of the aggregate wire is insulated 2. Description of the Related Art An insulated wire provided with an insulating coating formed by winding a tape and a coil using the insulated wire are known (for example, see Patent Document 1).

JP 2010-177075 A

A coil using a single insulated wire has a small loss in a band from DC to several kHz, but in a band higher than that, an eddy current caused by a magnetic field from a neighboring turn flows, resulting in a large loss.
On the other hand, since the coil using the conventional insulated wire is less likely to flow eddy currents than the coil using the single insulated wire, loss is reduced in a band higher than about several kHz. However, since the DC resistance value increases by the amount of the enamel layer at the same wire diameter, the loss increases in the low band.
However, for example, a motor coil is required to have a small loss on average from the time of startup to the time of high-speed rotation, that is, from direct current to high frequency. In addition, in the choke coil for switching power supply, since direct current and ripple current flow in a superimposed manner, it is also required that the loss is small on average from direct current to high frequency.
SUMMARY OF THE INVENTION An object of the present invention is to provide an insulated wire and a coil with a small average loss over a wide band from direct current to high frequency.

In a first aspect, the present invention provides a metal-coated conductor having a non-circular cross-sectional profile in which a metal coating of tin, tin alloy, zinc, or zinc alloy is formed on the outer periphery of a copper wire, a copper alloy wire, an aluminum wire, or an aluminum alloy wire. Provided with an insulated electric wire comprising a plurality of wires, and an aggregate wire whose overall cross-sectional profile is substantially square or substantially circular, and a first insulation coating that covers the outer periphery of the aggregate wire To do.
In the insulated wire according to the first aspect, a tin-based or zinc-based wire having a resistance four times or more higher than that of a copper wire, copper alloy wire, aluminum wire or aluminum alloy wire (tin-zinc alloy is included in both systems) Because the metal coating uses a copper wire, a copper alloy wire, an aluminum wire or an aluminum wire between the aluminum alloy wires, eddy currents can be suppressed, and loss at high frequency is reduced compared to single conductors of the same wire diameter I can do it. In addition, since this metal coating is not an insulator like an enamel layer, the increase in DC resistance is small, and if the wire diameter is the same as that of an insulated wire and coil using a conventional enamel layer, the loss at low frequency can be reduced. I can do it. That is, the loss can be reduced on an average over a wide band from direct current to high frequency.
In addition, tin-based and zinc-based metal coatings are easy to solder, which improves soldering performance compared to conventional insulated wires using enamel layers, and is advantageous for cost reduction and reliability during coil manufacturing. is there.
Furthermore, since a very dense oxide film with a thickness of several tens of nanometers is naturally formed on the surface of the tin-based or zinc-based metal coating, the oxide film is partially broken at the time of manufacture, but in other parts, the oxide film is broken. The oxide film can improve the corrosion resistance of copper wire, copper alloy wire, aluminum wire or aluminum alloy wire against gas, etc. (The oxide film is partially broken during the compression / extension process during manufacturing, and between metal coated conductors In the contact surface, the metals are joined and conductive.
In addition, when the entire cross-sectional outline is made into a substantially square shape (including a square shape to a rounded square shape), there is an advantage that a gap between lines when winding is reduced. On the other hand, when the entire cross-sectional outline is made into a substantially round shape (including a circle to a distorted circle), the outer periphery of the assembly line can be easily covered with tape.
Moreover, when an aluminum wire or an aluminum alloy wire is selected, a lighter wire can be obtained as compared with a copper wire or a copper alloy wire.

In order to make the entire cross-sectional outline substantially square, a plurality of lines are compressed through a substantially square die and then bundled in parallel without twisting, and immediately after forming a first insulating coating. The finished outer diameter can be made smaller than when twisted, and the wire length can be shortened, so that the DC resistance can be reduced. Moreover, since a twisting process is not required, productivity can be improved and manufacturing cost can be reduced.
In order to make the entire cross-sectional outline substantially circular, it is possible to manufacture a plurality of lines by compressing them through a substantially circular die and then bundling them in parallel. However, after compression, at an appropriate pitch (for example, 30 times or less of the layer core diameter) Good flexibility can be obtained by twisting. Also, since the assembly wire does not fall apart by twisting, it can be wound around the bobbin once before the step of forming the first insulation coating, that is, the assembly wire compression / twisting step and the subsequent insulation coating formation step. Can be divided.
The number of lines constituting the assembly line is preferably 4 or more from the viewpoint of improving the high frequency characteristics. Moreover, when compressing using the substantially circular die | dye for manufacture of an assembly line, it is preferable to set it as 11 or less from a compressive viewpoint.

In a second aspect, the present invention provides the insulated wire according to the first aspect, wherein the assembly line includes one or more bare copper wires, bare copper alloy wires, bare aluminum wires, or bare aluminum alloy wires. A featured insulated wire is provided.
In the insulated wire according to the second aspect, the copper cross-sectional area, the copper alloy cross-sectional area, the aluminum cross-sectional area, or the aluminum alloy cross-sectional area increases, so that it is useful for applications that place importance on the low frequency band from direct current.
Also, if the bare wire, the bare copper alloy wire, the bare aluminum wire, or the bare aluminum alloy wire are arranged so that they are not adjacent to each other at the center of the assembly line, the copper wire, the copper alloy wire, the aluminum wire, or the aluminum alloy at the center Since the metal coating of tin or tin alloy or zinc or zinc alloy is interposed between the wires to suppress the eddy current, the loss reduction effect can be increased (by the magnetic field from the neighboring turns of the coil or the core gap or nearby alternating magnetic circuit) If the eddy current is suppressed at the central portion, the loss reduction effect is greater than that at the peripheral portion).

In a third aspect, the present invention provides the insulated wire according to the first or second aspect, wherein the assembly wire includes one or more enamel-coated wires.
The insulated wire according to the third aspect is useful for applications in which a high frequency band is important because the eddy current can be completely cut off at the enamel-coated wire portion.
Also, if the enamel wire is arranged in the center of the assembly line, the enamel wire blocks the eddy current in the center, so the loss reduction effect can be increased (from the coil neighboring turns, core gap, nearby alternating magnetic circuit, etc. If the eddy current due to the magnetic field is blocked at the center, the loss reduction effect is greater than that at the periphery.
Further, if the outermost layer of the assembly line is arranged so that there is no enamel wire, the effect of improving the soldering performance can be maintained.

In a fourth aspect, the present invention provides the insulated wire according to any one of the first to third aspects, wherein a second insulating coating is formed on an outer periphery of the first insulating coating, and the second insulating coating is provided. An insulated wire is provided in which a third insulating coating is formed on the outer periphery of the wire.
In the insulated wire according to the fourth aspect, since the insulation coating has three or more layers, it is regarded as a reinforced insulated wire defined by safety standards, and when used in a high-frequency transformer used for a switching power supply, etc. It is possible to contribute to miniaturization of the high-frequency transformer, for example, by eliminating the need to provide an insulating partition.

In a fifth aspect, the present invention provides an insulated wire according to any one of the first to fourth aspects, wherein the insulating coating is formed by resin extrusion.
In the insulated wire according to the fifth aspect, the productivity can be improved as compared with winding the insulating tape.

In a sixth aspect, the present invention provides a coil characterized by winding an insulated wire according to any one of the first to fifth aspects.
In the coil according to the sixth aspect, the loss can be reduced on an average over a wide band from direct current to high frequency.

  According to the insulated wire and coil of the present invention, the loss can be reduced on average in a wide band from direct current to high frequency.

1 is a side view showing an insulated wire according to Example 1. FIG. It is A-A 'sectional drawing of FIG. It is sectional drawing which shows the wire bundle for manufacturing the insulated wire which concerns on Example 1. FIG. 1 is a perspective view showing a coil according to Embodiment 1. FIG. 3 is a graph showing frequency characteristics of a coil according to Example 1; 6 is a cross-sectional view showing an insulated wire according to Example 2. FIG. 6 is a cross-sectional view showing an insulated wire according to Example 3. FIG. 6 is a cross-sectional view showing an insulated wire according to Example 4. FIG. 10 is a side view showing an insulated wire according to Example 5. FIG. FIG. 10 is a B-B ′ sectional view of FIG. 9. It is sectional drawing which shows the wire bundle for manufacturing the insulated wire which concerns on Example 5. FIG. 10 is a graph showing frequency characteristics of a coil according to Example 5.

  Hereinafter, the present invention will be described in more detail with reference to embodiments shown in the drawings. Note that the present invention is not limited thereby.

Example 1
FIG. 1 is a side view illustrating an insulated wire 101 according to the first embodiment. 2 is a cross-sectional view taken along line AA ′ of FIG.
The insulated wire 101 is composed of a collection wire 11 in which nine metal-coated copper wires 4 having a non-circular cross-sectional outline are gathered in parallel and the overall cross-section outline is substantially square, and an outer periphery of the collection wire 11 is extruded. A first insulating coating 1 formed by coating, a second insulating coating 2 formed by resin coating the outer periphery of the first insulating coating 1 by extrusion, and a second insulating coating 2 formed by resin coating the outer periphery of the second insulating coating 2 by extrusion. 3 insulation coating 3.
The metal-coated copper wire 4 is obtained by forming a metal coating 4b of tin, tin alloy, zinc or zinc alloy on the outer periphery of the copper wire 4a.

FIG. 3 shows, for example, a center line 4 obtained by electroplating a metal coating 4b ′ of tin or tin alloy or zinc or zinc alloy with a thickness of 1 μm or less on the outer periphery of a copper wire 4a ′ having an outer diameter of 0.63 mm and a circular cross section. And an outer layer wire 4 "electroplated with a metal coating 4b" of tin or tin alloy or zinc or zinc alloy on the outer periphery of a copper wire 4a "having a circular cross-sectional profile of 0.39 mm in outer diameter and having a thickness of 1 µm or less. A set line 11 ′ is shown in which 8 are arranged in parallel.
The collective wire 11 ′ is compressed and expanded through a square die having a diameter of 1.0 mm to manufacture the collective wire 11 (compression / extension process), and resin coating is performed on the outer periphery of the collective wire 11 in three stages. By the (extrusion coating process), a 1 mm square insulated wire 101 can be continuously manufactured.
It is preferable that the metal coating 4b ′ and the metal coating 4b ″ are melted by heat when passing through the die or separately, and then cooled to melt the wires.

FIG. 4 is a perspective view showing a coil 20 formed by winding an insulated wire 101 around a core 21 in a solenoid shape.
The core 21 is an iron core having a diameter of 20 mm.
The number of turns of the coil 20 is 20 turns.

FIG. 5A is a frequency-resistance value characteristic of only the copper loss of the coil 20 shown in FIG.
The resistance value is expressed as a relative value to the DC resistance value of the coil having the same structure except that a round single wire (DCR standard) having an outer diameter of 1 mm is used.
FIG. 5b shows the frequency-resistance characteristic of the coil having the same structure except that the enamel coating is used instead of the metal coating 4b.
FIG. 5 c shows the frequency-resistance characteristic of the coil having the same structure except that a 1 mm square single wire is used instead of the insulated wire 101.
FIG. 5f shows the frequency-resistance characteristic of a coil having the same structure except that a round single wire (DCR standard) having an outer diameter of 1 mm is used.
It can be seen that the coil 20 of the first embodiment can reduce loss on average in a wide band from direct current to high frequency. For example, in a 48-pole motor, a high frequency of 1.2 kHz to 3.6 kHz is obtained at 3000 rpm to 9000 rpm, but it can be seen that the loss of the coil 20 of Example 1 is the smallest at 1.2 kHz to 3.6 kHz.

-Example 2-
FIG. 6 is a cross-sectional view illustrating the insulated wire 102 according to the second embodiment.
This insulated wire 102 is obtained by replacing the outermost metal-coated copper wire 4 of the insulated wire 101 of Example 1 with the bare copper wire 5 instead of one. Reference numeral 12 denotes a collective line.
The insulated wire 102 is superior in characteristics in a low frequency band as compared to the insulated wire 101 of the first embodiment.

-Example 3-
FIG. 7 is a cross-sectional view illustrating the insulated wire 103 according to the third embodiment.
This insulated wire 103 is obtained by replacing the metal-coated copper wire 4 at the center of the insulated wire 101 of Example 1 with an enamel-coated copper wire 6. 6b is an enamel coating. Reference numeral 13 denotes a collective line.
The insulated wire 103 is superior in characteristics in a high frequency band as compared with the insulated wire 101 of the first embodiment.

Example 4
FIG. 8 is a cross-sectional view illustrating the insulated wire 104 according to the fourth embodiment.
The insulated wire 104 is a rounder square shape than the insulated wire 101 of the first embodiment. This can be produced by changing the shape of the die.
Compared to the insulated wire 101 of Example 1, the insulated wire 104 is formed by winding an insulating tape when the first insulating coating 1, the second insulating coating 2, and the third insulating coating 3 are formed by winding an insulating tape. It becomes easier to wind.

-Example 5
FIG. 9 is a side view illustrating the insulated wire 201 according to the fifth embodiment. 10 is a cross-sectional view taken along the line BB ′ of FIG.
The insulated wire 201 is composed of a collective wire 11 in which seven metal-coated copper wires 4 having a non-circular cross-sectional outline are gathered in parallel and the overall cross-sectional outline is substantially circular, and an outer periphery of the collective line 11 is extruded. A first insulating coating 1 formed by coating, a second insulating coating 2 formed by resin coating the outer periphery of the first insulating coating 1 by extrusion, and a second insulating coating 2 formed by resin coating the outer periphery of the second insulating coating 2 by extrusion. 3 insulation coating 3.
The metal-coated copper wire 4 is obtained by forming a metal coating 4b of tin, tin alloy, zinc or zinc alloy on the outer periphery of the copper wire 4a.

FIG. 11 shows, for example, a metal-coated wire obtained by electroplating a metal coating 4b ′ of tin or tin alloy or zinc or zinc alloy with a thickness of 1 μm or less on the outer periphery of a copper wire 4a ′ having an outer diameter of 0.4 mm and a circular cross section. A set line 11 ′ in which 7 pieces of 4 ′ are assembled in parallel is shown.
The assembly line 11 ′ is compressed and expanded through a circular die having a diameter of 1.0 mm to produce the assembly line 11 (compression / extension process), and resin coating is performed on the outer periphery of the assembly line 11 in three stages. By the (extrusion coating process), the insulated wire 201 having an outer diameter of 1 mm can be continuously manufactured.

12d shows the frequency-resistance value characteristic of only the copper loss of the coil having the same structure as that of the coil 20 shown in FIG. 4 except that the insulated wire 201 is used.
The resistance value is expressed as a relative value to the DC resistance value of the coil having the same structure except that a round single wire (DCR standard) having an outer diameter of 1 mm is used.
FIG. 12e shows the frequency-resistance characteristic of a coil having the same structure except that enamel coating is used instead of the metal coating 4b.
FIG. 12 f shows the frequency-resistance characteristic of a coil having the same structure except that a round single wire (DCR standard) having an outer diameter of 1 mm is used.
It can be seen that the coil of Example 5 shown in FIG. 12d can reduce loss on average in a wide band from direct current to high frequency. For example, in a 48-pole motor, a high frequency of 1.2 kHz to 3.6 kHz is obtained at 3000 rpm to 9000 rpm, but it can be seen that the loss of the coil of Example 5 is the smallest at 1.2 kHz to 3.6 kHz.

-Example 6
The outermost metal-coated copper wire 4 of the insulated wire 201 of the fifth embodiment may be replaced with the bare copper wire 5 instead of one. In that case, compared with the insulated wire 201 of Example 5, it becomes the thing excellent in the characteristic in a low frequency band.

-Example 7-
The metal-coated copper wire 4 at the center of the insulated wire 201 of Example 5 may be replaced with an enamel-coated copper wire. In that case, compared with the insulated wire 201 of Example 5, it becomes the thing excellent in the characteristic in a high frequency band.

-Example 8-
A circular shape that is more distorted than the insulated wire 201 of the fifth embodiment may be used. This can be produced by changing the shape of the die.

-Example 9-
A copper alloy wire may be used instead of the copper wire of Examples 1 to 8.

-Example 10-
An aluminum wire may be used instead of the copper wire of Examples 1 to 8.

-Example 11-
Aluminum alloy wires may be used in place of the copper wires of Examples 1 to 8.

  The insulated wire and coil of the present invention can be used for motors, switching power transformers, and the like.

DESCRIPTION OF SYMBOLS 1 1st insulation coating 2 2nd insulation coating 3 3rd insulation coating 4 Metal coating copper wire 4a, 4a ', 4a "Copper wire 4b, 4b', 4b" Metal coating 5 Bare copper wire 6 Enamel coating copper wire 6b Enamel coating 11, 11 'Collecting wire 20 Coil 21 Core 101-104, 201 Insulated wire

Claims (6)

A plurality of non-circular metal-coated conductors with a cross-sectional contour formed by forming a metal coating of tin, tin alloy, zinc, or zinc alloy on the outer periphery of a copper wire, copper alloy wire, aluminum wire, or aluminum alloy wire. An insulated wire comprising: a collecting line having a substantially square or substantially circular cross-sectional outline; and a first insulating coating covering an outer periphery of the collecting line. 2. The insulated wire according to claim 1, wherein the assembly wire includes one or more bare copper wires, bare copper alloy wires, bare aluminum wires, or bare aluminum alloy wires. The insulated wire according to claim 1 or 2, wherein the assembly wire includes one or more enamel-coated wires. The insulated wire according to any one of claims 1 to 3, wherein a second insulating coating is formed on an outer periphery of the first insulating coating, and a third insulating coating is formed on an outer periphery of the second insulating coating. An insulated wire characterized by that. The insulated wire according to any one of claims 1 to 4, wherein the insulating coating is formed by resin extrusion. A coil comprising the insulated wire according to any one of claims 1 to 5 wound thereon.

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